Strengthen a D35

[Waytec]

I am in need of some suggestions for how to strengthen a D35.
I have been wanting to re gear and locked my rear end since about my 3ed trip out. But the cost to gear and lock a 8.25 is superiorly more then a 35. Also used parts are allover the place for them. So I have gotten a D35 and a used locker and am going to put it under my Cherokee.
 Before I do so I want to strengthen the D35 first. This done all the time but I can not find info about how to do so. So any suggestions or links on how to do so would be great.
Thanks

[Immortal]

Thought you had the 8.25 in the rear?

[cLAY]

The phrase "polishing a turd" pretty much sums up the wisdom of putting money into a "turdy5".


Look for a D44, 8.25, explorer diff........

[calltrex]

96+ explorer 8.8 diff  with disc brakes


Id rather have the 8.8 open then the wimpy D35 locked



if u can live with drum brakes instead pre-96 you can get a 8.8 for $100


I bought one for $100

[Waytec]

I have an 8.25 now and D44's people want left arms for. So far I have less then $100 into a D35 that is geared and a ARB locker. I can reinforce this diff and have no issues unless someone has an 8.25 or a D44 geared and locked for me at those prices. I will take it.
Back to the issue at hand. How is the best way to reinforce a D35.   

[sylvrinvader]

as far as i know use a truss

[frenchy]

Truss might help the axle tubes, but all of the internals are still going to be junk. A locker will only make them break easier.

[BlackYJ]

Truss might help the axle tubes, but all of the internals are still going to be junk. A locker will only make them break easier.

Not always the case if you understand the forces.  It is usually high instantaneous stress that breaks the shafts like when you are spinning a tire and suddenly get traction.  It is true that locker do put a higher continous stress on the shafts which can aid in breaking a shaft

Now I locked my D35 with an ARB and I actually felt safer than when I was open.  The reason being is that I did not need nearly as much momentum or skinny pedal to go hills or tough obstacles.

Since you are set on building a D35 and you probably don't have a super kit in there, I would look at truss the housing and getting alloy shafts.  With that combo you should definitely be okay with 31s and if you make the step to 33s for awhile.  A lot of people jump on the brand wagon and bash the D35 but 31s or 33s it can be a decent axle if built right and the driver realizes it a D35.  Denise's D35 took a CRAP load of abuse and last a long time

[Waytec]

Thanks Scott
I will defiantly look into a super kit. As for a truss is their anywhere I can go to get info about putting a truss on.

[calltrex]

is it a c-clip or non c-clip ??

[Waytec]

non c-clip

[WhiteOut]

Check out Mountain Valley Customs, they have a truss/skid that a few guys on JF run.

[BlackYJ]

I will defiantly look into a super kit.

The Super kit requires a new locker as it is 30 spline shafts, but I would talk to ARB and ask is you can just swap the spider gears for some 30 spline ones.  I know you can do that on the newer D30 ARBs

[Gearhead]

Not to be negative like on pirate 4x4 BUT .............................

As mentioned 

 
You could go ahead with your plan anyway .  At this stage it appears inexpensive when in fact , if it grenades , leading to a second axle build  / repair  or aquisition / build if it blows up real good , the cost could be a real shock if you are not prepared for it.  I should mention the potential hassle of dragging it out of the back country , towing , etc.



Here's a D35 shaft  next to a D44 (Waggy)



If you build it and it breaks , the ridicule and guffawing could get outa hand , hope you don't mind some teasing.



Lots of us  have run D35's , I still own two vehicles with D35's neither of them get wheeled or do any towing. I've also seen Dana 35's survive a savage pounding a number of times as well as snap an axle turning a corner at the mall.

Think it over before spending money.

[Waytec]

Because Gearhead is so set on me not building a D35 I guess he will gladly trade me a D44 with a air locked and gears for the D35, locker and gears I have now. So Pm me with your address and I will come by this weekend to get it.